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Kidney Gearbox Project  Rate Topic 
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 Posted: Tue Jan 19th, 2021 03:41 pm
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Louis Luu
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My new year resolution is to get that dang Kidney gearbox done.  I have started a post here to remind myself to hurry up and finish the project and get them out to those who need them.  Please don't ask me about the gears...that will be done but after mini lollipop...have a sweet tooth.  Feel free to kindly remind me to get it done here...post here.  I will be making sure the width of the wall is fix this weekend and fill with bondo....by the end of this weekend!  I will post pictures of my progress here.  
And I know I am going to get questions as to which gearbox...this is the one hole version.  I will not be making anymore two hole version....all you have to do is drill it out for a second hole....problem solved.  My goal for the second box is to fix all the original casting imperfections.  Original casting had uneven thickness.

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 Posted: Tue Jan 19th, 2021 03:45 pm
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Louis Luu
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I also heard back from George that the double wing bronze pointers were all sold out. I will be making one last batch. If you need them...please post here...easier to keep track of instead of emails. Our emails has no search feature...pain to find things!

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 Posted: Tue Jan 19th, 2021 04:46 pm
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Andrew Sampels
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Hello Louis,
Just a quick reminder of the Kidney version B gearbox castings.

Thanks a bunch for your effort on all of this. I know the community appreciates it.

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 Posted: Thu Jan 21st, 2021 03:19 pm
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Steven P Dempsey
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are the 16 & 12 the same? I have a 16" stump

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 Posted: Thu Jan 21st, 2021 03:23 pm
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Louis Luu
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Both same. There are two different version gearbox (1 hole vs 2 hole). I'm making it easy...only doing the 1 hole version. If 2 hole version is needed...easy fix...drill the second hole.

I am fixing some minor flaws in the original casting...wall thickness. Made some progress. Will sand today. I will post pictures later.

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 Posted: Thu Jan 21st, 2021 05:44 pm
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Steven P Dempsey
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great - - I ordered the remaining brass parts for my Kidney

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 Posted: Thu Jan 21st, 2021 09:36 pm
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Don Tener
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For some people it might be easier to get the 2 hole version. I installed the gears from a 1 hole box by just getting a olite bushing. No machining needed. Some members here can not drill a hole that precisely.

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 Posted: Thu Jan 21st, 2021 10:04 pm
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Louis Luu
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One hole version only. I'm trying to cut on the time and cost. A simple press drill will get the job done. There are plenty of people here who can help...great AFCA members here. I just want to finish and move on to other things. I've gotten the thickness I want. Just priming and sanding needed. Then a clear coat of acrylic and mold making. Once done...I will leave with the caster and let them pour. Last time I participated in pouring...it wore me out. Pouring metal is a lot of heavy lifting and really need to be careful.

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 Posted: Thu Jan 21st, 2021 10:47 pm
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Louis Luu
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Sorry for the bad photo...sunlight.  Here is the before and after.  I got the correct even thickness.  Just need to prime and smooth out.  Then a clear coat of acrylic.  Once done...I will make the mold.






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 Posted: Thu Jan 21st, 2021 10:50 pm
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Louis Luu
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Took me awhile...not very good working with bondo...fragile as heck, but really easy to file down. Once I prime and clear coat it...it will be easier to work with.

The top will have the same treatment.  I will make sure they are perfectly aligned with no issues. 

Last edited on Thu Jan 21st, 2021 10:52 pm by Louis Luu

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 Posted: Thu Jan 21st, 2021 11:40 pm
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David Kilnapp
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Louis: Your work is very impressive - masterful!

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 Posted: Thu Jan 21st, 2021 11:53 pm
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Louis Luu
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How the heck do you guys work with this bondo...fragile as heck.  I'm using the slow curing bondo...because I work slow....and mess up easily.  I'm not very good with this...much better at working with lost wax casting...much easier.

David Kilnapp wrote: Louis: Your work is very impressive - masterful!

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 Posted: Fri Jan 22nd, 2021 12:36 am
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Louis Luu
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This slow cure red bondo...nice working time...but fragile.  Do you guys have a favorite bondo.  This is the one I'm using.



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 Posted: Fri Jan 22nd, 2021 01:46 am
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Patrick Ray
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Personally I hate anything Bondo brand. I like products from Evercoat. I've done a bit of body work on cars and messing with Bondo just makes me hate life. Evercoat is much easier to work with and holds up better.

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 Posted: Fri Jan 22nd, 2021 01:53 am
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Louis Luu
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Thanks Patrick...I'll look into it. That bondo...I don't know...just flakes too easily.

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 Posted: Fri Jan 22nd, 2021 02:15 am
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Russ Huber
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Thanks again, Louis! 

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 Posted: Fri Jan 22nd, 2021 02:17 am
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Louis Luu
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Russ...with the thicker edge...this should make the lid sit properly...less bending of the wax.

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 Posted: Fri Jan 22nd, 2021 02:26 am
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Patrick Ray
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Louis Luu wrote: Thanks Patrick...I'll look into it. That bondo...I don't know...just flakes too easily.
No problem Louis!  Evercoat has been my go-to for body work and I've used it to fill in heavy imperfections on fans.  Just so much nicer to work with.  It's not expensive either.  I get mine from a local auto body store, but some better auto parts stores (like NAPA) might have it as well.  I think you can also get it on Amazon. 

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 Posted: Fri Jan 22nd, 2021 02:39 am
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Louis Luu
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I do see it on Amazon...do they carry any slow cure formulation?

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 Posted: Fri Jan 22nd, 2021 02:46 am
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Patrick Ray
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When I want more working time, I just reduce the amount of the creme hardener I mix in. I've kinda got an eye for how much I mix. When doing automotive work, it's about a hockey puck glob of filler with two toothpaste beads of hardener... If that made any sense. You get about 5 min of working time before it starts to lock up and isn't workable.

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 Posted: Fri Jan 22nd, 2021 02:50 am
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Louis Luu
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Thank you.

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 Posted: Mon Jan 25th, 2021 03:04 am
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Louis Luu
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Cold as heck. It started raining Saturday and so I was doing bondo work and sanding in the pantry where it was warmer...missed a critical delivery...really bummed out. I did manage to work on the top gearbox and match the thickness...priming was impossible due to the weather...really bummed out that I miss a critical delivery. I will be heading down to the post office to pick up a fan I have been waiting for over 8 years to get! I will post pictures...this fan will blow your mind! I've been dreaming of this fan for a very long time and I can't believe I missed it. Work has been slow due to the weather. The goal is to have the gearbox all done by end of month and get it casted. Stay tune for some awesome posting of my favorite fan tomorrow.

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 Posted: Mon Feb 1st, 2021 10:28 pm
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Louis Luu
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Just an update...I have not forgotten. Been working on the badge and the box. I have been doing bondo work and profiling both top and bottom...weather is cold and takes awhile to cure...been putting in the oven after my other half goes to sleep. What she does not know won't hurt her. Box is coming along just fine and should be ready to go out in about a month...you will be happy with the end product. I wanted to make sure the second molding pattern is perfect!

Last edited on Mon Feb 1st, 2021 10:28 pm by Louis Luu

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 Posted: Wed Feb 10th, 2021 11:44 pm
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Louis Luu
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I finally got the even thickness I wanted and fix the curvature for the top lid.  Next step is to prime and make the mold.







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 Posted: Thu Feb 11th, 2021 01:19 am
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George Durbin
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Dang! That is beautiful!!

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 Posted: Thu Feb 11th, 2021 01:24 am
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Louis Luu
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The curvature on the lid is actually more pleasing...at least to me. Original curvature on the lid look "flat" to me. The original lid and box wall had uneven thickness. The red areas are what is added. Compare the left and right sides of the lid and box...note one side has more bondo put on to make it even.

This is the same on all the box I looked at...I decided if new castings are going to be made...might as well fix.

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 Posted: Thu Feb 11th, 2021 01:38 am
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Louis Luu
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Here is the original lid...flat and boring.



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 Posted: Thu Feb 11th, 2021 02:05 am
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Louis Luu
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Here is the original gearbox...very uneven.  Compare the right and left sides.  The right side is much thicker.

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 Posted: Thu Mar 18th, 2021 05:15 am
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Louis Luu
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Molding will be end of this week. I have time to put the finishing touches and begin making the mold. I decided to not mess with the curvature...keep it as original as possible. The only thing I fixed was the uneven lip.

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 Posted: Sun Mar 21st, 2021 09:21 pm
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Louis Luu
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I'm sorry it took so long. Finally finishing up. I took several feedbacks. Forgot who, but someone mention if I thicken it...I would loos the details of the letters. I made sure through trial and error...lots of errors that the letters were detailed while making the top a bit thicker and a bit extra to fix the uneveness to both the top and bottom and uneven lip. Than I took Russ' feedback...make sure it sits properly. Finally got that done...a lot of trial and error as well. Finally, I made sure to adjust for the shrinkage by doing multiple measurements...pain in the butt. The single hole version will be much better as this will allow those who have the two hole version to simply drill. Finally, a personal touch...make it really nice even and smooth. The mold will go out this Friday/Saturday. Using the oven to fast dry. I will cast the majority in bronze and some in steel for myself...one time. These will be $220/each with free shipping. Hope George does not mind helping out with shipping. Also, I made one last batch of the double pointers...all bronze.

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 Posted: Mon Mar 22nd, 2021 12:48 am
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George Durbin
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Don't mind at all Louis!

Send them on and we will make some members very happy!


Geo...

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 Posted: Mon Mar 22nd, 2021 01:54 am
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Patrick Ray
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I know I'm very much looking forward to getting one of these Kidneys!  I'm sure there's lots of fans out there waiting for your craftsmanship!

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 Posted: Mon Mar 22nd, 2021 02:40 am
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Dennis Long
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Louis, thank you so much for your willingness to take on this project and to be willing to make it a success through pain-staking attention to detail and a desire to produce a top-quality product!
BTW, did you ever post pics of your 8-year search fan?

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 Posted: Mon Mar 22nd, 2021 02:43 am
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Louis Luu
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Yes.  VSM/Stellite.  Another casting project down the line.

http://www.afcaforum.com/view_topic.php?id=62035&forum_id=1&highlight=vsm

Dennis Long wrote: Louis, thank you so much for your willingness to take on this project and to be willing to make it a success through pain-staking attention to detail and a desire to produce a top-quality product!
BTW, did you ever post pics of your 8-year search fan?

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 Posted: Sat Apr 17th, 2021 08:40 pm
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Louis Luu
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Just dropped off a whole bunch of lost wax casting for the gearbox....160 of them. I will be casting 150 in bronze and 10 in steel.

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 Posted: Sat Apr 17th, 2021 08:42 pm
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Louis Luu
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Also, Double wing bronze pointers will be ready in two weeks. This will be my last batch. I will be doing more focus on the mini-lollipop project. more grinding and modification to the stem. I want it to look like the 12 inch but in miniature 8 inch form.

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 Posted: Sat Apr 17th, 2021 09:39 pm
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Patrick Ray
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Great to hear! Thank you for all of your hard work on this project. Can't wait to get one of your bronze Kidneys on my fan!

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 Posted: Sat Apr 17th, 2021 09:45 pm
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Louis Luu
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I'll be making some Bronze ring to go with the bronze gearbox for those interested in having one sometime next week.

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 Posted: Sat Apr 17th, 2021 09:48 pm
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Patrick Ray
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When are you anticipating on being able to ship these? Also, will we order these from you or from George like the pointers were done?

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 Posted: Sat Apr 17th, 2021 09:52 pm
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Louis Luu
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George has kindly volunteered to help out with the shipping. Please do not pay yet until I pick up the gearbox. I will have badges and double wing pointers available in two weeks.

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